Molded fibre article



July 8, 1947. CHAPUN 2,423,756

MOLDED FIBRE ARTICLE Filed Dec. 1'7, 1943 4 Sheets-Sheet 1 INVENTOR.

y 1947- M; P. CHAPLIN 2,423,756

MOLDED FIBRE ARTICLE Filed Dec. 17, 1943 4 Sheets-Sheet 3 July 8, 1947-M. P. CHAPLIN MOLDED FIBRE ARTICLE Filed Dec. 17, 1943 4 Sheets-Sheet 4Patented July 8, 1947 MOLDED FIBRE ARTICLE Merle P. Chaplin, SouthPortland, Maine Application December 17, 1943, Serial No. 514,684

9 Claims.

This invention relates to molded fibre cartons, and particularly to acarton suitable for packing fragile objects such as eggs. The drawingsherein referred to illustrate a. carton suitable for packing eggs in tworows of six eggs per row, a

or a total of one dozen eggs. This is known to the trade as the 2 x 6carton. It is, however, understood that the invention is not limited toa carton if this sizeor shape, nor is it limited exclusively to thepacking of eggs.

By molded fibre carton is meant an article formed from a mixtureoffibres and liquid on a contoured die, shaped to the approximate size andkind of object to be'made. This is in contradistinction to an articlefor a similar purpose, but fabricated from flat sheet material.

Molding from liquid fibre mixtures enables shapes and forms to beproduced not possible or practicable where fiat sheet materials areemployed. Preferably the article of this invention, after forming onsuitably shaped 'dies, is dried between other heated dies to preservethe exact shape and form of the article, and to impart to its surfacedistinctive finishes.

There are many specific and novel features herein disclosed which can bebest understood by reference to the following description and drawings,in which:

Figure 1 is a top .plan view of the carton show with its two part coveropen.

Figure 2 is a transverse sectional view alon the line 2-2 of Fig. 1looking in the direction of the arrows.

Figure 3 is a top plan view of the carton with the covers closed.

Figure 4 is an end elevation of the carton with the covers closed. v

Figure 5 is a side view of the carton shown with the covers closed.

Figure 6 is a lengthwise sectional view along the lines 66 of Fig. 3 andlooking in the direction of the arrows.

Figure? is a cross-sectional view takenon line i| of Fig. 5 and lookingin the direction of the arrows.

Figure 8 is a bottom view of the carton similar to that shown in Fig. 1but with. planular side walls in the bottom section.

Figure 9 is a somewhat enlarged fragmentary view, partly in section,illustrating a 1ocking tab Figure 11 is a fragmentary plan view of thepocket section of Fi 1, slightly enlarged to show the side wallconstruction. 7

Figure 12 is a fragmentary end elevation partly in section of the sidewall structure of Fig. 11,

Figure 13 shows the hinge construction bev tween the pocket and coversections when the covers are open.

Figure 14 shows the position taken by the hinge section when the coversare closed.

Figure 15 is a section through one of the article receiving areasconsiderably enlarged to show the flexure of the walls of the centralsupportving members for the article.

Figure 16 shows a modified structure of the article receiving area whereflexible sections are molded integrally with the rest of the structureto provide greater flexibility for the supporting areas of the articlereceiving cavity.

Figure 17 shows the structure of the bottom support for the articlewhere the article is supported on a special cushion member, forming apart of the rest of the molded fibre structure.

Containers or cartons for eggs, or other similar fragile objects, arecustomarily made by two generally diflerent methods. One is a fabricatedcarton made from flat sheet board, and the other is a carton molded orformed to its desired shape by some pulp forming process or method.

The carton made or fabricated from board is limited in its design andconstruction, as board can be bent or formed in one direction only. Itis not possible to secure shaped, curved, or other irregular surfacesfrom a sheet of board without destroying its strength.

In order to provide suflicient flexibility for the packaging of articlessuch as eggs, it is frequently necessary, in cartons made from board, tostrip,

cut, or otherwise weaken certain egg supporting areas in order, toprovide suflicient flexibility for the proper cushioning of the eggs.

In making cartons by a pulp molding or fibre molding process, many ofthe limitations of shape and contour necessary in a board carton areeliminated, as, within reasonable limits, it is possible to shape amolded article to fit or meet any desired contour or irregular shape.

Heretofore, in making cartons for the packing of eggs and similarobjects .by a pulp moldingprocess, it has been thought necessary to makethe walls of the carton rather thick, heavy, and soft, in order toprovide an adequate cushioning for the egg surfaces.

n order to impart to the article sumcient softness or cushioningqualities, it has been necessary to materially detract from itsstrength, rigidity, and sturdiness. Also the thickness and bulk-oi sucha type of molded carton is high, and considerable packing space isrequired both to pack and ship cartons for use, and also considerableextra space is taken up by the pulp detracting from the useful egPacking space.

'By methods and processes, not a part of this application, ways andmeans have been found to mold fibre objects to any desired shape andcontour and still have them strong and rigid, and their surfacescomparable in smoothness and texture with the smoothest of board orsimilar materials, which have been well calendered or finished in sheetform. This at once removes two of the objections of soft bulky moldedarticles, in that strength is restored and its surface is smooth,attractive, and can be printed in colors or decorated in any desiredmanner.

With the restoration of strength and surface finish to the article it isstill necessary that adequate cushioning means he provided which willyield to cushion the eggs against shock, and will also yield to permitthe packing of larger eggs, while still holding the smaller eggs againstshaking around or vibration within the carton itself. These should beaccomplished without slitting or otherwise weakening the strong smoothstructure and, therefore, must be accomplished by features of design andconstruction of the carton itself.

Means must also be provided so that when the carton is closed forshipment, after being filled with eggs, that the cover or covers aresecurely locked in place, so that the carton cannot by any possibilitycome open accldentallmand allow the eggs to be exposed or spilled out,This locking means must hold the covers securely in place, be easy toaccomplish, and not require the use of any added material such as aclip, string, or tape for securing the covers in closed position. Nevertheless, when it is desired to open the carton, to take out the eggs, itmust be opened without material difficulty, although it may necessitatethe rupture of some part of the locking device, which, of course, servesas an indication that the carton has been opened and would be useful inpreventing tampering with eggs while in storage.

One additional feature regarding this particular carton as shown is thatits outside size must be such that will permit it to be packed in astandard thirty dozen egg case or crate with 15 cartons in each end orsection of this crate. This is the standard egg crate used for packingeggs in bulk, where thirty dozen eggs are packed, fifteen dozen in eachend or section of the crate, in five layers with three dozen eggs oneach layer. In such a standard bulk packing, adjacent eggs are separatedonly by a relatively thin cardboard separator or filler, and itconsequently follows that,

. when eggs are packed in dozen cartons, there must be a minimum ofspace between cartons, or eggs in adjacent cartons in order that thecartons themselves can be packed in the standard case without wastingspace.

This feature and limitation as to carton size, makes it absolutelynecessary to reduce the thickness or bulk of the carton as much aspossible, and to utilize all of the available space inside the cartonfor the eggs themselves, while still maintaining the eggs out of contactwith each other, and also protect them from all reasonable shocks fromthe outside of the carton itself.

Referring to the-several figures before enumerated, Figure 1 shows thecarton viewed T he top with its two cover members open and the carton inposition to receive a dozen eggs.

The carton itself consists of a bottom or egg containing section, showngenerally at l0 and H, with cover sections l2 and I3. These two coversections are connected by means of specially molded integral hinges tothe opposite sides of the egg receiving portions l0 and II, these hingesbeing shown generally at 2|. The side walls of the carton can be madegenerally straight or planular as indicated in Fig. 8, but preferably Imake them in a pilastrade, or a series of pilasters, in order to givethe side walls stiffness, rigidity, and strength, and also to,provide,in part, the egg or article receiving cavity. These pilastrated sidewall structures are joined at their ends by two curved sections, H,which form the end of the carton, and also form, in part, egg receivingcavities. The side walls consist generally of the pilaster portions I6(see Figs. 1, 11, and 12) and the intermediate portions Ilia. Eachcurved end section II, of the carton forms, in efiect, an end pilaster,and at the same time, a connecting member to the center of the cartonwhere it joins a second member H, which ties in with the opposite cartonwall.

Referring particularly to Figures 11 and 12, it will be observed thatthe wall section on each longside of the carton is greatly increased instrength over and above what would be obtained if a single flat straightwall was employed as shown in Figure 8. The bending moment of the wallis, in effect, the distance between the outermost portions of the wallI6 and Ilia, as shown in Fig. 12, in contradistinction to themerethickness of the stock of the side wall, were a planular singlestraight wall employed as is shown in Fig. 8. To space the eggs fromeach other both lengthwise and crosswise in the carton, there isarranged through the center of the carton a plurality of flat sidedpyramids l4. Five such pyramids are shown and they are positioned .withthe axial planes of their conforms one of the cavity defining walls forthe egg or other article.

These pyramids M are made with long fiat sides molded and finished tohave strength and rigidity in a vertical direction for supportingpurposes, but flexible between their converging edges to permit yieldingwhen eggs of difierent sizes are inserted in the carton. Referring moreparticularly to Fig. 15, which is a sectional, view looking down on thecarton and through the approximate center of the area which supports thee it will be observed that the egg on one side is supported within thecurved area of one of the side wall pilasters l6, while the other issupported on a wide flat surface on two adjacent center members I 4.

In this figure, the circles e and e indicate eggs of small and largesize. The full lines show the support of a. small egg e, in that the eggis contacted on a plurality of sides, so that it is held from shakingaround or moving within the carton, which is objectionable.

ward the outside or the carton-so is a maximum oi space between adjacenteggs at all times. However, when large eggs are packed which is a verynecessary feature'of all cartons in order that they may take and holdthe largest eggs, they must necessarily come nearer to each other, andthe center support structure permits this, while definitely assuringthat they do not touch each other.

It has already been pointed out that the outside size of the carton islimited by thefact that it must be packed with other cartons in acertain definite space. In order to insure that there be the maximumspace between the eggs in any carton, I pack the eggs against thepilastrated outside walls, or the cushions in these outside walls, andhold the eggs or other articles in their proper places between thepilastrated sections by means of the flexible walls of the innerpyramidal striictures. The outside walls are prevented from movingoutwardly under the added pressure of "eg s from the inside, both byreason of their structural design, and also because they are tied "1 as;t. '1. and abut preferably .1. employ an" integral structure in Fig.1'7.

shown considerablyenlarged,

This structure is made not a part of this application. However, thiscommodates itself to the shape of the eg and can be pressed downwardwhenever long eggs are packed in the container, which, when the cover isclosed, requires the extra space and necessitates that the bottom.of'the egg come together at the top by means of the interlocked coversections. As larger eggs are packed in the carton, the long fiat wallsof the pyramid sections will be flexed inwardly as shown in Fig. 15,until the maximum size of egg has been reached, and all of the spaceinside the carton utilized. Under this condition the eggs areindividually held firmly between the two flexed walls of two adjacentpyramid sections, and the recess between the pilasters in the outerwalls, thereby firmly retaining the egg in position, and preventing itfrom vibrating or shaking against or coming in contact with adjacenteggs.

In order that the eggs may be adequately protected from the outside, twomethods may be used either in conjunction with each other, or one may beused alone. Referring particularly to Fig. 14, this shows, considerablyenlarged, the outside of the carton at the hinge line, or at the line ofgreatest egg diameter. It will be observed that the hinge structure hereemployed, adequately protects the egg against shock from the outside, orfrom an egg in an adjacent carton, by providing a series ofconvolutions, yielding in their nature and located directly opposite theegg at its largest diameter. Another method which I may employ in orderto further cushion eggs, particularly where it is desired to pack eggshaving extra thin shells or where it is desired to handle them verycarefully for incubating or other purposes is shown in Fig. 16.

For this extra cushioning I may, in the side walls of the interiorsupporting members [4 or in the walls of the pilasters l6 providecushion members, which will serve as flexible cushions over the areawhich the eggs will contact, without detracting from the strength andsupporting characteristics of the remainder of the carton.

Some similar, but not as effective means, may be had by providingthickened or soft sections at these points as is generally shown at 20,Fig. 1. While these relatively soft sections provide a certain amount ofcushioning, they do, however, have the objection of taking addedspace,particularly when the cartons are nested for shipment and at the best,they do not provide as good a support, particularly so far as resiliencyand flexibility is concerned, as do the structures shown in Fig 16.

For supporting the egg at the bottom, I may employ a soft pulp area ineach of the egg receiving areas, such as is generally shown at 19 innearer to the bottom of the carton. as is shown by the dotted line in Fi1'7.

For further stiffening of the carton lengthwise in addition tothepilaster structure of the side walls,'I preferably connecttheinteriorsupporting members It by a series of hollowjnrib members i8, asshown in Fig. 1 and 8, ,These 35nnecting hollow rib members are shown insection in Fig. 3. 5'"

Besides providing longitudinal strength, the

rib sections 18, connectingthe members l4, provide an air space beneaththe carton, which can communicate with the interior of the carton byproviding holes or openings I5 in the top of each one of the centermembers I4. This will provide ventilation within the carton insuringbetter refrigeration of eggs in storage.

The cover members i2 and 13 are connected to the upper portion of thepilastered side walls to and Ilia by means of hinges M, as alreadymentioned. The shape of the two cover portions are such that they willnest when open as in Fig. 2, but when closed they will match evenlyaround the ends of the bottom section, and close together in theposition as shown in Figs. 4 and 7.

The outer portions of the walls of the covers l2 and it are flaredoutwardly as indicated at 22 of cover section 62, and 23 of coversection 63. In order that they may swing inwardly from the flared ortapered position shown in Fig. 2, to the locking position shown in Fig.7, a hinge is provided on cover portion H3 at 26 and on cover portion 92at 2'? and 28. V

In addition to the hinge portion extending along the entire length ofcover portion is at 26, there is provided on each end, and adjacent tothe hinge portion and the curved end portions, a plurality of connectedhinged sections 29, to permit the flared portion of the cover I3 toswing inwardly about its hinge 26 from the flared position of Fig. 2 tothe vertical position of Fig. '7. When the flared portion 23 of thecover [3 swings inwardly, the hinges at 29 flex, and the severalsections between them move to a nearer vertical position, permitting theportion 23 to assume a full vertical position and adjacent to thecompanion part on cover l2.

Similarly, on cover i2, there are hinges provided between the portions22, the locking portions 24, and the main cover part I2, these hingesbeing indicated at 21 and 28. Similarly, there are a plurality of hinges29a in the tapered wall to permit the end sections on the side of thecover to bend inwardly from the flared position showrzi in Fig. 2 to thevertical position shown in Fig.

. For securing the two cover sections l2 and iii in closed position,there is provided a plurality of locking tabs 24 in cover portion l2 anda similar number of locking slots 25 on cover portion i3. In closing thecarton the central portions 22 of cover l2 contacts the tapered portion23 of cover 53,

apart: of the in its integral molded ilbre formation-by j and both arepressed against each other, swinging each portion into a vertical planeas indicated in Fig. 7.

At the same time that the covers are closed together, locking tabs 24are inserted in slots 25, and after the covers are completely closedthey assume the position where they are locked together by the tabs asshown in Fig. '7. It has already been pointed out that the several hingeareas 29 and 29a permit the flared portions, longitudinal or lengthwiseof the cover portions, to bend inwardly into locking position. When thecovers are in locked position, the portion 23 of cover 13, or the edgeof this portion rests directly on the tops of the central members I4,thereby providing a vertical support for the cover when other cartons ofeggs are packed on top. Portions 22 of cover I2 similarly rest theiredges on the tops of portions l4, forming an additional support for thecover sections l3 in addition to that afforded by the tabs which lookcover i3 to cover I 2.

It will be noted that the hinge areas 2|, between the base sections land II, and the cover portions l2 and l3,are located somewhat above thecenter of the carton depth- This provides the widest area opposite theportion of the egg of greatest diameter which is somewhat above itscenter when the egg is packed small end downward as is customary. Fig.14 illustrates the position of the largest portion of the egg diameterrelative to the hinge 2| and shows the protection afforded the bulge ofthe egg by the hinge structure itself. This is not only shown in Fig. 14considerably enlarged, but also in Fig. 7, on a somewhat reduced scalefrom actual carton size.

It will also be noted that the tops of portions M are located somewhatbelow the hinge line of the carton, so that when portions 23 and 22contact each other and are pushed all the way down to the top of partsl4, they will be somewhat below their hinge center, and therefore,have'a tendency to go farther due to the natural springiness of thehinge portion between parts of the two covers.

For locking the tabs 24 in slots 25, the width of the slot is madesomewhat less than the width of the tabs as is indicated in Fig. 9. Whenthe tab is pushed all the way into the slot the edges of the slot 25bend downwardly as indicatediin Fig. and thereby lock the tabs inposition at both edges. This prevents thecarton from openingaccidentally and securely locks the cover portions of the cartontogether until it is desired to open them to remove the eggs.

It will thus be seen that I have provided a simple molded fibrestructure, which has incorporated in itself, a considerable number ofnovel features necessary to the proper packing of articles such as eggs.As already stated, I preferably finish my molded fibre article betweenheated dies both to retain the article in exact size and shape and alsoto provide its surfaces with a smooth, attractive finish not possiblewhere the ordinary pulp sucking methods of molding are employed and thecarton oven dried or by similar drying methods.

I also provide an outer wall structure, pilastratedin form, and madefirm and rigid, eliminating all flexibility or yielding which mightresult in the eggs being broken or injured by contact from the outside.Where it seems necessary, I may provide over certain areas of theseoutside rigid. walls, cushioning members. Preferably, however I providethe cushioning means in the center areas of the cartons, as has alreadybeen described, in order that my outside walls may be left firm andrigid to properly protect the eggs against damage by contact either withother cartons, or with the walls of the packing case.

Generally speaking,the eggs are held in position against the outer orpilastrated walls, or against cushions in these walls, the pyramidsections through the center of the carton yielding as much as isnecessary in order to provide for the different sizes of eggs.The'ultimate yielding, of course, provides space to fill the entirecentral area of the carton with eggs, so that eggs crosswise the cartonand adjacent to each other, may be fairly close together, but definitelyseparated by the springy action of the long fiat walls in the pyramidsections themselves.

By providing hinge sections as here shown, I protect the egg or row ofeggs at the point of the greatest diameter by a corrugated memberrunning the entire length of the carton and opposite all of the eggs inthe outside rows, this assuring that the eggs, at their largest and mostexposed area, are further protected in addition to any cushion memberwhich may be located in the carton wall itself.

For these and other novel features shown on the drawings and hereindescribed I make the fol lowing claims:

1. A molded fibre egg carton comprising: a car ton body havingrelatively rigid outer side walls provided at spaced apart distanceslongitudinally thereof with internally concave egg engaging portions andsaid body having a bottom provided, between said side walls, withintegral projections extending into the confines of the body instaggered relation to the concave egg engaging portions of the sidewalls and presenting to eggs, positioned between said concave eggengaging portions and said projections, relatively yieldable surfacesadapted to bend to compensate for eggs of different diameters, said bodybeing provided with relatively rigid multiple bowed end walls connectingthe opposite ends of the side walls to provide within said end wallsadditional internally concave egg engaging portions facing yieldablesurfaces of the end projections interiorly of the body, and coversintegrally hinged to the opposite side walls of the carton body, saidcovers having bowed ends of greater radius than the adjacent bow in theend walls of the carton body when the covers are open and provided withintegral bendable sections to cause the bowed ends of the covers toconform with the multiple-bowed end walls of the body when the coversare closed.

2. A self-locking molded fibre egg carton comprising: a carton bodyhaving a bottom provided, between outer side walls, with a row ofupstanding compartment forming knobs, the upper ends of which constitutecover supporting'abutments positioned below the upper edges of the sidewalls, and integral covers hinged to the upper edges of the oppositeside walls of the body and having flanges at'their free edges adapted tofacially 'engage one another with their free edges resting upon saidabutments when said covers are closed.

3. A self-locking molded fibre egg carton comprising: a carton bodyhaving a bottom provided, between outer side walls, with a row ofupstanding compartment forming knobs, the upper ends of whichconstitutecover supporting abutments positioned below the upper edges of the sidewalls, integral covers hinged to the upper edges of the opposite sidewalls of the body and having flanges at their free edges adapted toracially engage 9 I one another with their free edges resting upon saidabutments when said covers are closed, and means integral with saidcovers to interflt and lock said covers in closed position.

4. A self-locking molded fibre egg carton comprising: a carton bodyhaving a bottom provided, between outer side walls, with a row ofupstanding compartment forming knobs, the upper ends of which constitutecover supporting abutments positioned below the upper edges of the, sidewalls, and integral covers hinged to the upper edges of the oppositeside walls of th body and having flanges at their free edges adapted tofacially engage one another with their free edges resting upon saidabutments when said covers are closed,

,one cover being slotted and the other cover having at least one taperedcooperating tab of greater width than the length of the cooperating slotto fit into such slot under stress and lock the covers closed.

5. A molded fibre egg carton comprising: 'a compartment body having sidewalls, chambered covers pivoted to the upper edges of the opposite sidewalls of the body by interposed integral corrugated hinge sections, saidbody being of so much less depth than said covers that when eggs are setupright within the body compartments, with their small ends down, thehinge sections will be juxtaposed with the points of greatest diameterof such eggs to cushion such eggs against external shock. a

6. A molded fibre egg carton comprising: a compartment body having sidewalls, chambered covers pivoted to theupper edges of the opposite sidewalls of the body by interposed integral corrugated hinge sections, saidbody and covers being of such unequal depth that eggs may be positionedin upright manner in the compartments of the body with the hingesections juxtaposed with the points of greatest diameter of such eggs tocushion such eggs against external shock.

'I. A molded fibre egg carton comprising: a carton'body havingrelatively rigid'outer side walls provided at spaced apart distanceslongitudinally thereof with internally concave egg engaging portionshaving downwardly inclined horizontally curved egg engaging surfaces andsaid body having a bottom provided, between said side walls, withintegral upwardly projecting posts extending into the confines of thebody in staggered relation to the concave egg engaging portions of theside walls and presenting to eggs, positioned between said-concave eggengaging portions and said projecting posts, relatively yieldablesubstantially flat surfaces adapted to bend to compensate for eggs ofdifferent diameters, said body being provided with relatively rigidmultiple bowed end walls connecting the o opposite ends of the sidewalls to provide within said end walls additional internally concave eggengaging portions facing yieldable surfaces of the end projectionsinteriorly of the body.

8. A molded fibre egg carton comprising: a body having side walls andend walls, the former provided at spaced distances longitudinallythereof with relatively rigid egg seats interiorly concave in thedirection of the length of the walls and with substantially straightsurfaces in the direction of the depth of ,the body, a bottom wall and acover integral with and respectively tying together the side walls atthe bottom and top of the body whereby the overall width of the body ismaintained substantially constant irrespective of the sizes of the eggsin the body, andtapering hollow compartment-forming knobs integral withsaid bottom wall and extending into the confines of the body instaggered relation to the concave egg seats of the side walls to formbetween each two adjacent knobs and the interposed rigid egg seat of theadjacent side wall a compartment adapted to receive an egg, adjacentknobs being provided with broad substantially plane peripheral wallsarranged in converging relation to the adjacent side wall and adapted toyieldably engage an egg which is in non-yielding engagement with suchinterposed rigid concave seat.

9. A molded fibre egg carton comprising: a

carton body having a bottom provided, between outer side walls, with arow of upstanding compartment forming knobs, the upper ends of whichconstitute cover supporting abutments, and integral covers hinged to theupper edges of the opposite side walls of the body and having flanges attheir free edges adapted to facially engage one another with their freeedges resting upon said abutments when said covers are closed.

MERLE P. CHAPLIN.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 2,093,280 Koppelman Sept. 14,1937 2,160,893 Newsom June 6, 1939 1,975,129 Sherman Oct. 2, 19341,543,443 Koppelman June 23, 1925 2,285,129 Schwartzberg June 2, 19421,124,713 Degginger Jan. 12, 1915 1,990,145 Swift Feb. 5, 1935 FOREIGNPATENTS Number Country Date 363,893 Great Britain Dec. 31. 1931

